Table of Contents
Chapter
First Aid for
1:
Introduction to Automotive
Heating,
First Aid for Skin
Air
11
Conditioning, and Ventilation
Heating, Ventilating,
(HVAC) Systems
and Air
Conditioning
Conditioning
System Operation
/ Defrost
Tools, Equipment, and
Layer
HVAC
23
Test
System Service Tools
Service Tools
Protection
27
28
Proper Clothing and
28
Protective
Equipment / Eye
Protection / Foot and Hand Protection
Kinds of Accidents
Liquid Refrigerants / Rules for
Vapor
Refrigerants
Hose Tools
/
/ Orifice Tube Tools / Oil
51
Recovery/Recycling Equipment/Flushing Equipment/
Evacuation Pumps / Recharging Equipment / Air
Purging Equipment
Engine Cooling System Test Equipment 54
Pressure and Leak Testers / Antifreeze Testers
/
Combustion Leak Testers
29
Maintaining a Safe Workplace / Performing Work
Procedures Properly
34
Refrigerant Safety Precautions
and
40
47
Injectors
Refrigerant Service Equipment
and Environmental
Safety Equipment
Equipment
Compressor Service Tools / Compressor Clutch
2:
Causes of Accidents
39
Service Information
Gauges
/ Ventilation / Air Conditioning
The Air Conditioner and the Ozone
Personal
HVAC
3:
Gauge Manifolds / Temperature Gauges / Leak
Detectors / Refrigerant Identifiers / Electrical Test
Equipment / Belt Tension Gauges / Vacuum Pumps/
20
Conditioning / Ventilating / Heating
21
System History
Shop Safety
Chapter
Diagnostic and
Mechanical Devices
Chapter
Liquid
Agency
Refrigeration System Parts and Operation / Heating
System Parts and Operation / Air Delivery System
Parts and Operation
19
HVAC System Controls
Heaters
35
/ Prevent Gaseous Waste
Protection
Environmental
The
/
Contamination
and Air
12
System Components
HVAC
Preventing Environmental Damage
Waste Contamination
Why Is It Called HVAC?
Heating, Ventilation,
Air
Exposure / First Aid for Eye
Breathing Difficulty
Exposure / First Aid for
Prevent Solid Waste Contamination / Prevent
12
Major
HVAC
35
Refrigerant Exposure
Handling
Vehicle Protection
56
Service Information
57
Factory Manual / General Manual / Specialized Manual /
Technical Service
Bulletins/Telephone Hotlines/
Internet Resources
Table of Contents
7
Other
4:
Chapter
HVAC Electrical and Electronic Fundamentals.. 63
Electrical Basics
64
Conductors and Insulators / Electrical Measurements /'
Direct and
Alternating Current / Types
of Electrical
67
Vehicle Wiring and Electrical Components
Hoses and Lines
68
Wiring / Wiring Schematics / Circuit Protection
Devices / Switches / Solenoids, Relays, and Magnetic
Clutches / Motors / Resistors / Capacitors
Basic Electrical Diagnosis
75
Electrical Device Not
at
Working /
Electrical Device
on
All Times
Vehicle
Computers
75
Semiconductor Materials / Computer Circuits /
Control Loops / Main Computer Sections / Computer
Diagnostic Outputs
Chapter
of
Refrigeration
81
Purpose of Refrigeration
Basic
82
Principles of Refrigeration
82
Heat and Cold / Heat Transfer /
Sensible and Latent
Change of State /
Heat/The Pressure-Temperature
109
110
Hoses / Metal Lines / Combination Hose and Line
Assemblies / Hose and Line Attachments / Hose and
Line Size
Specifications
Refrigeration System Fittings
112
Compression Fittings / Crimp Fittings / Spring Lock
Couplings / Screw Type Hose Clamps / Service
Fittings
Making Hoses, Lines, and Fittings 116
Refrigeration Sealing Devices
Shaft Seals /
Compressor
116
O-ring Seals / Sealing
Washers / Gaskets
Refrigeration Components
Types of Refrigeration Systems /
/
Accumulator
/ Compressor / Muffler /
Evaporator
Condenser / Receiver-drier / Filter /
Seals
and
8:
Compressors, Clutches, and
Compressor Purposes
Basic Compressor Parts
Types of Compressors
Scroll
85
The Two Main
Flow Restrictor /
Chapter
Piston
Relationship
Connecting
Lines
Gaskets / Which Parts
Sight
Glass /
/ Service Fittings /
Are Used
on
Which
91
122
Compressors / Rotary Vane Compressors /
Compressors
Control Valves
Compressor
Capacity
Compressor
Drives and Clutches
130
130
/ Compressor Clutches /
Compressor
Clutch
Control Systems / Constantly
Compressor
Engaged Compressor Clutch
135
Bosch / Calsonic /
Cooling Phase—Evaporator / Pressure
Phase—Compressor /
121
122
Compressor Makes and Models
Refrigeration Cycle
Drives
122
Drive
Systems? / Refrigerants
The
and Seals
5:
Principles
The
105
Leak Detector
Dyes / Evaporator Surface Cleaners / Refrigeration
System Sealers
Chapter 7:
Hoses, Lines, Fittings,
Circuits / Circuit Defects
Electromagnetism
Refrigeration System Chemicals
Flushing Compounds /
Desiccants /
Delco
Increase
Heat Transfer Phase—
Chrysler / Frigidaire/Harrison/
Air/Delphi / Ford / Hitachi / Keihin /
Condenser / Pressure Decrease Phase—Flow
Matsushita/Panasonic / Mitsubishi / Nihon/Nihon
Radiator / Nippondenso / Sanden/Sankyo / Seiko-
Restrictor / Factors That Affect System Performance
Seki / Seltec / Tecumseh/York / Unicla / Zexel/Diesel
Kiki / Older
Chapter
Compressors
6:
Refrigerants, Refrigerant Oils,
Chapter
and Related
Chemicals
97
98
Refrigerant Purposes
Refrigerants and Governmental Regulation
98
Refrigerant
Blended
Classification
Condensers
R-12
versus
Condenser
101
Refrigerants (Azeotropic
Evaporators
143
144
Evaporator Design and Construction / Types of
Evaporators / Parts Attached to the Evaporator
99
R-134a / R-12 (Freon) / R-134a
Evaporators, Condensers, Accumulators, and
Receiver-Driers
Montreal Protocol / Clean Air Act
Types of Refrigerants
9:
and
Zeotropic
Blends) / Drop-in Refrigerants / New Refigerants
102
Replacement Refrigerants
Choosing a Replacement Refrigerant /
104
Refrigerant Oils
of
Types
Refrigerant Oil
146
Design
Accumulators
Receiver-Driers
SNAP
Program
148
Accumulator Operation
148
Desiccants
Pressure Relief Devices
150
Auto
8
Chapter
HVAC Control
10:
153
Control Valves and Switches
Two
Ways
to
Control Evaporator Temperature
Expansion Valves
Thermostatic
and
Equalizers
Electronic
154
of
Evaporator
157
Pressure
Cycling
Switches / Thermostatic
and Valves
Pressure Cutoff Switches
Switches
/ Thermal
163
Older
/ Temperature Cutoff
Chapter
168
Cooling System
Engine Cooling System Operation
and Air Bleeds
Thermostat
Heater—Liquid-Cooled Engine / Heater—Air-Cooled
Engine
Heating System Components 180
Liquid-Cooled System / Air-Cooled System
Chapter 12:
Air Delivery Systems
Air
Blowers and Motors
186
186
Blower Wheels / Blower Motors
Air Ducts and
Heater/Evaporator
Intake Ductwork / Heater and
Output
Ductwork
Air Doors and
/ Vents /
Operating
Cases
Evaporator
Independent
Devices
Devices/Cabin Filters
/
Vents
Temperature
233
Functional and Performance Tests / Leak Detection
Step 4—Eliminate Other
Causes of the Problem
5—Recheck the Cause of the Problem
Always Perform Additional
Control /
Tests
246
Step 6—Correct the Defect
Step 7—Recheck System Operation
Deciding
on
246
246
Repairs
Chapter 16:
Refrigerant Recovery, Recycling,
Handling
Service
Rules for
and
251
252
Handling Refrigerants / Using a Refrigerant
Refrigerant to a Partially Charged
Identifier / Adding
System
Operating
Recovering
R-134a
254
or
R-12
/ Recovering Blends and
Recycling Refrigerant
Evacuating Refrigeration Systems
199
200
Humidity
/
243
243
Needed Work
Recovering Refrigerant
13:
System Purposes
228
the Driver
Contaminated Refrigerant /
Manual HVAC Controls
Control
Cases
190
Blend Door / Diverter Doors / Door
Chapter
Talking
228
232
Step 2—Check for Obvious Problems
Step 3—Determine Which System Is Causing the
Refrigerant
187
Procedure
Step 1—Determine the Exact Problem
to
228
Proceeding Logically
Documentation of
Handling Systems
and Leak
227
Follow-up
185
Systems
228
Seven-Step Troubleshooting
Step
179
Systems/
Control
Detection
Problem
/ Blower / Shrouds / Oil Cooler /
223
15:
Refrigeration System Diagnosis
The
Jackets / Coolant Pump /
Coolant Pump Drive Belts / Radiator / Radiator Fans /
Thermostat / Coolant Hoses / Pressure Cap / Coolant
Heating System
Temperature
Temperature
The Importance of
168
Water
Fins
Control
Strategy-based Diagnostics
168
Engine Cooling System Components
168
Liquid-cooled Engines
Engine Cooling
System Operation /
Electromechanical
167
Recovery Systems / Drains
Air-Cooled Engines
178
Control Heads /
Temperature Control Systems
Mechanical
Limiters
Vehicle Heaters
Engine
/ Control
Control System
Computer Self-diagnosis
Parts
Chapter 11:
Engine Cooling Systems and
Coolants /
214
Systems
Automatic and Semiautomatic
Sensors
System Protection Switches
14:
Types of Controls / Temperature Control Loops
215
Electronic Temperature Control Systems
161
Temperature Cycling Switches / Pressure and
Temperature
Systems
Automatic Control
Pressure Controls
Types
Compressor Clutch Controls
200
203
Automatic Temperature Control Systems ..213
156
Evaporator Pressure Controls
Conditioning
System Parts / Electrical and Electronic Controls
/ Compressor Controls / HVAC Electrical System
Protection Devices / Control System Operation
Chapter
Expansion Valves
& Air
Control
154
156
System Modes
Manual Control
Springs / H-blocks
Fixed Orifice Tubes
Heating
Control / Airflow
257
Evacuation Procedure
Flushing Refrigeration Systems 258
Open Loop Flushing / Closed Loop Flushing
Table of Contents
9
Checking and Adding Oil
Checking Compressor
Scroll Compressors / Capacity Control Valve
Removal and Replacement / Replacing Other
259
Oil Level /
Adding
Oil
to
Compressor Components
Charged System / Adding Oil to Replacement
Components / Adding Oil to the Compressor
a
Vacuum and Pressure
Overhauling Older Compressors
Testing Refrigeration
Chapter 19:
Valve, Evaporator, Condenser, and Related
261
Systems
Testing / Nitrogen Pressure Testing
Recharging Refrigeration Systems 262
Vacuum
Parts Service
Recharging with Refrigerant Service Center/
with Gauge Manifold / Refrigeration
System Purging
264
Installing an Inline Filter
the Filter-Drier /
Replacing
Center's Scale
Checking
Service Centers
/
Calibrating
Changing
Installing
a
264
Receiver-Drier
the Service
New Tank
/
Evaporators
and
O-rings
Crimped Fittings / Hose Clamps
Replacement 274
Making Hoses
Replacement
/
Installing
and
Fittings
276
Replacement / Making
Lines
279
Compressor and Clutch Problems
Compressor Clutch
Not
Engaging /
Occasional Low Pressure
Compressor Removal and Replacement
282
Compressor Removal / Adding Oil to Compressors /
Compressor Installation / Compressor Retrofitting
284
Compressor Clutch and Electromagnet Service
Clutch Removal / Electromagnet and Clutch
Poor
Guidelines / Receiver-Drier
309
Engine Cooling System
Compressors / Overhauling
No
Heating /
Engine Overheating
Heater Service
Too Much Heat
/
/ Coolant
Engine
of Air-cooled
Overcooling
323
Changing Heater Hoses and Shutoff Valves
Changing Heater Cores
327
Liquid Cooling System Service
/
Changing Coolant and Flushing the Cooling
System / Belt and
Hose
Replacement
/ Thermostat
Replacement / Cooling Fan Replacement / Coolant
Pump Replacement / Radiator Replacement
Shaft Seal
Piston
or
322
Engine Cooling System Problems
Coolant
Leaks
Causes
/
/
Overheating
287
Replacement / Rebuilding Compressors /
Overhauling Radial Piston Compressors/
313
Leaks / Heater Problems—Air-cooled
Replacement
Overhauling Axial
Replacement
314
Safety Considerations
314
Cooling System Inspection
Checks
Cooling System
320
Heating System Problems
280
Excessive Pressure / Constant Low Pressure /
Compressor Overhaul
Accumulator
309
Service
Compressor and Clutch Service
Noises /
Replacement Guidelines/
Receiver-Driers
Heater and
Crimping
18:
Common
307
Chapter 20:
Hoses
Removal and
Cleaning / Condenser Replacement
Accumulators
Replacement
Systems with Multiple Component Units
274
Selecting Proper
307
Replacement
274
Hose Removal and
Condensers
Condenser
Gasket
Hose Service
Afterblow Module Installation
270
Compression Fittings / O-ring Replacement / Spring
Lock Couplings / Service Fittings
273
Servicing Hose Fittings
Line Service
303
Evaporator Cleaning / Evaporator Replacement /
Servicing Fittings
Chapter
Switches
17:
Hose
301
Expansion Valves / Evaporator Pressure Control
Valves / Orifice Tubes / Compressor Cycling
Air
Hose, Line, Fitting, and O-ring Service.... 269
Line
Component Service
Adding
Refrigerant from a Disposable Tank / Removing
from Charging Cylinders
Chapter
298
Expansion Valve Failures / Orifice Tubes / Evaporator
Pressure Control Valves / Compressor Cycling
Switches / Evaporator / Condenser / Accumulator /
the Vacuum Pump Oil /
for Leaks /
297
Common Problems
Charging
Maintaining Refrigerant
294
Air
Cooling System
Cleaning Fins
Blower Belt /
on
Service
an
333
Air-cooled Engine /
Replacing Blower
Replacing Thermostat
and
Replacing
Bearing /
Auto
10
Chapter 21:
Air Delivery
Taking the
Types
and Manual HVAC Control
Service
Air
338
Blower Motors and Related Parts / Cabin Filter/Air
Intake Filter / Ducts and Air Doors / Manual Control
Panels
Air
Delivery and Control System Service
Blend Door Cable
Adjustments / Removal and
of
Replacement Components / Checking Afterblow
Modules
Chapter
22:
Automatic
Temperature
353
Control
System
Electronic Temperature Control
Control System Self-Diagnosis
Problems
354
359
Temperature Control System Testing
Testing Input Sensors / Testing Output Devices /
Mechanical Temperature Control Systems /
Electromechanical Temperature Control Systems
Electronic Temperature Control System Service
360
Computer Reprogramming/Control Head/
Temperature Control Computer / Air Temperature
and Sunload Sensors / Replacing Output Devices
Adjusting
System Service
364
Installation and
375
Retrofit / Level of Retrofit /
Retrofit
to
Performing
384
Other ASE Activities/ASE Test Windows
Applying for the ASE Tests 385
Department
Store
Specialty Shops / Independent Repair Shops / Fleet
Agencies / Government Agencies / Self-Employment
Other
Opportunities in the Auto Service
Industry
398
Shop Supervisor
or
Service
Manager / Salesperson
or
Service Advisor / Parts Person
a
Job
399
Appendix A:
Components
and
403
Operation
Operation / Older Rear Window Defoggers
Diagnosis
Defroster Service
404
405
406
and
Relays / Repairing the
Useful Tables
411
Acknowledgments
414
Glossary
415
Index
ASE Certification
394
a
24:
ASE Tests
394
Auto Service Centers / Tire, Muffler, and Other
Window Grid
Aftermarket Air Conditioner
Chapter
Servicing
Replacing Switches
368
Conditioning Kits / Aftermarket
Conditioning Considerations / Installing an
Complete
and
393
New Vehicle Dealers / Chain and
Defroster
Aftermarket Air
Retrofitting
Refrigerant Recovery
388
Rear Window and Mirror Defrosters
367
Whether
388
Helpers / Apprentices / Certified Technicians
395
Types of Auto Service Facilities
Defroster
Retrofitting
R-12 to R-134a
388
Chapter 25:
Career Preparation
Defroster
Air
Confidentiality
Finding Job Openings / Applying for the Job
Replacing System
Parts / Power Servo /
Amplifiers
Aftermarket Air Conditioners
387
388
Recycling
Getting
Transducer Cables /
Chapter 23:
Air Conditioning System
Questions
Recertification Tests
Systems / Electronic
Electronic
Mechanical and Electromechanical
385
Levels of Automotive Service Positions
Service
System
Technician
Automotive
Automatic Temperature Control
Conditioning
Questions/Incomplete Sentence Questions
Test Results
Certification in
342
& Air
One-part Questions/Two-part Questions/Negative
337
Delivery and Manual Control System Problems
ASE Tests
of ASE Test
Heating
383
425